Abstract: A method can comprise: scanning, via an optical scanner, a tip of an airfoil of a bladed rotor, the tip including a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; comparing a coating parameter of the coating to a coating parameter threshold based on scanner data from the optical scanner; and determining whether the coating maintains sufficient coverage of the tip of the airfoil based on the comparing.

Abstract: A method can comprise: scanning a tip of an airfoil of a bladed rotor, the tip including a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; comparing a coating parameter of the coating to a coating parameter threshold based on scanner data from the scanning; and determining whether the coating maintains sufficient coverage of the tip of the airfoil based on the comparing.

Abstract: An inspection device is disclosed herein. In various embodiments, the inspection system device comprises: a support structure; a motor; a shaft operably coupled to the motor, the shaft extending from a first side of the support structure to a second side of the support structure, the shaft configured to couple to a bladed rotor; and a scanner moveably coupled to the support structure, the scanner configured to generate a three-dimensional model for the bladed rotor.

Abstract: A method is disclosed herein. The method can comprise: receiving, via a processor, scanner data from an inspection system for a bladed rotor, the scanner data including a point cloud defining an inspected bladed rotor, the scanner data including a first data size; generating, via the processor, a reduced data set from the scanner data, the reduced data set having a second data size that is less than the first data size; and transmitting, via the processor, the reduced data set to an analysis system for the inspected bladed rotor.

Abstract: A method of determining a repair method for a defect in a bladed rotor can comprise comparing the defect in a three-dimensional model of an inspected integrally bladed rotor (IBR) to a plurality of known defects from a repair database; determining the defect is matching a known defect in the plurality of known defects in the repair database; and generating a repair process associated with the known defect in response to determining the defect is matching the known defect. A method can also comprise determining a potential repair process; performing a structural simulation of a finite element model for the inspected IBR with the potential repair; performing an aerodynamic simulation of an aerodynamic model for the inspected IBR with the potential repair; and generating the potential repair process for the defect in response to determining the inspected IBR with the potential repair meets structural and the aerodynamic criteria.

Abstract: A method can comprise: receiving, via a processor, scanner data from an inspection system for a bladed rotor, the scanner data including a point cloud defining an inspected bladed rotor, the scanner data including a first data size; generating, via the processor, a data set including section files spaced apart along a span of a blade based on the point cloud; determining, via the processor, a defect on the blade of the inspected bladed rotor based on the data set; and determining whether the defect meets serviceable limits.

Abstract: A method can comprise receiving, via the processor, one of a point cloud and a three-dimensional model for an inspected integrally bladed rotor (IBR) and a defect including a defect shape, a defect size, and a defect location; performing, via the processor, a simulation of a rotor module in a gas turbine engine, the rotor module including the inspected IBR with a potential repaired defect; determining, via the processor, the potential repaired defect would produce an estimated life less than a design life for the inspected IBR; determining, via the processor, the estimated life would exceed a remaining life threshold for the inspected IBR; and generating, via the processor, a repair process for the potential repaired defect.

Abstract: A method can comprise: determining, via a processor, whether serviceable limits are met for an inspected bladed rotor; generating, via the processor, a three-dimensional model including a repair blend profile for a defect in response to determining the inspected bladed rotor does not meet the serviceable limits; performing, via the processor, a first set of simulations on the three-dimensional model; determining, via the processor, whether a first set of results of the first set of simulations meet an experience based criteria; performing, via the processor, a second set of simulations on the three-dimensional model in response to a first result in the first set of results not meeting a first objective parameter in the experience based criteria; and determining, via the processor, whether a second set of results and the first set of results meet a deterministic criteria.

Abstract: An article of manufacture may include a tangible, non-transitory computer-readable storage medium having instructions stored thereon that, in response to execution by a processor, cause the processor to perform operations comprising: commanding, via the processor, a first scan of a bladed rotor; generating, via the processor, a three-dimensional model based on a first set of data received from a first scanner; comparing, via the processor, the three-dimensional model to an acceptable three-dimensional model of the bladed rotor; determining, via the processor, areas of interest based on the comparison; and commanding, via the processor, a contact probe to perform a non-destructive inspection on the areas of interest.

Abstract: A method of correcting a twist angle of a gas turbine engine blade includes measuring an existing twist angle of the blade, applying a first angular load to a first end of the blade; and measuring a repaired twist angle of the blade. The first angular load applied to the first end of the blade is based on an empirical correlation between a plurality of angular loads necessary to produce a plurality of twist angle correction values.

Abstract: A method of developing a repair process for a gas turbine engine component deformed during engine operation includes determining peak stress locations in a model of the component, applying loads to sample components based on the model to produce geometrical correction values in the samples, generating data from the samples including the loads applied and the geometrical correction values produced, destructively analyzing the samples at the peak stress locations for structural imperfections, and correlating the loads applied to the geometrical correction values produced to determine allowable loads necessary to produce target geometrical correction values in a used component substantially free of structural imperfections.

Abstract: A method of developing a repair process for a gas turbine engine component deformed during engine operation includes determining peak stress locations in a model of the component, applying loads to sample components based on the model to produce geometrical correction values in the samples, generating data from the samples including the loads applied and the geometrical correction values produced, destructively analyzing the samples at the peak stress locations for structural imperfections, and correlating the loads applied to the geometrical correction values produced to determine allowable loads necessary to produce target geometrical correction values in a used component substantially free of structural imperfections.

Abstract: A method of correcting a twist angle of a gas turbine engine blade includes measuring an existing twist angle of the blade, applying a first angular load to a first end of the blade; and measuring a repaired twist angle of the blade. The first angular load applied to the first end of the blade is based on an empirical correlation between a plurality of angular loads necessary to produce a plurality of twist angle correction values.